Method and Apparatus for Manufacturing Pneumatic Tyres

ABSTRACT

A green tyre disposed on a toroidal support is introduced into a vulcanisation mould. The mould is closed through axial approaching of a pair of half shells acting against the sidewalls and the tread band of the tyre. Circumferential sectors set to operate against the tyre tread band are maintained spaced apart from the tread band itself during admission of a working fluid designed to press the tyre against the toroidal support. Subsequently the sectors are centripetally approached to cause penetration of forming ridges movable in through slits into the tread band, concurrently with a step of full moulding and vulcanisation of the tyre carried out through admission of steam under pressure into the tyre itself.

CROSS REFERENCE TO RELATED APPLICATION

This application is a national phase application based on PCT/IT2004/000730, filed Dec. 28, 2004, the content of which is incorporated herein by reference.

The present invention relates to a method and an apparatus for manufacturing pneumatic tyres for vehicle wheels.

In a tyre production cycle it is provided that, subsequently to a building cycle in which the different tyre components are manufactured and/or assembled, a moulding and vulcanisation process be carried out which is aimed at defining the tyre structure according to a desired geometry, usually having a particular tread pattern.

To this aim, the tyre is enclosed in a moulding cavity defined internally of a vulcanisation mould and conforming in shape to the geometric configuration of the outer surfaces of the tyre to be obtained.

A pneumatic tyre generally comprises a carcass structure of a ring-shaped toroidal conformation, including one or more carcass plies strengthened with reinforcing cords lying in radial planes, i.e. in planes containing the rotation axis of the tyre. Each carcass ply has its ends rigidly associated with at least one metallic annular anchoring structure, usually known as bead core, constituting the reinforcement to the beads, i.e. to the radially internal ends of said tyre, the function of which is to enable assembling of the tyre with a corresponding mounting rim. A band of elastomeric material referred to as tread band is applied crownwise to said carcass structure, and in said tread band at the end of the vulcanisation and moulding steps a raised pattern is formed for ground contact. Placed between the carcass structure and the tread band is a reinforcing structure currently known as belt structure. This belt structure usually comprises, in the case of tyres for cars, at least two radially superposed strips of rubberised fabric provided with reinforcing cords, usually of metal, disposed parallel to each other in each strip and crossed with the cords of the adjacent strip, preferably symmetrically disposed relative to the equatorial plane of the tyre. Preferably said belt structure, at least on the ends of the underlying strips, further comprises a third layer of textile or metallic cords that are circumferentially disposed (at 0 degrees), at a radially external position.

Respective sidewalls of elastomeric material are also applied to the side surfaces of the carcass structure, each extending from one of the side edges of the tread band until close to the respective annular anchoring structure to the beads.

Finally, in tyres of the tubeless type, i.e. devoid of air tube, there is the presence of a radially internal layer having impermeability features to ensure airtightness to the tyre, said layer being generally referred to as “liner”.

To the aims of the present description it is herein to be pointed out that by the term “elastomeric material” it is intended a composition comprising at least one elastomer polymer and at least one reinforcing filler. Preferably, this composition further comprises additives such as cross-linking agents and/or plasticizers. Due to the presence of the cross-linking agents, this material can be cross-linked through heating, so as to form the final article of manufacture.

There are moulding and curing methods in which a green tyre is set within the mould, being placed on a substantially rigid toroidal support. Said methods are preferably used for tyres that, based on recent manufacturing processes, are produced starting from a limited number of elementary semi-finished products fed onto a toroidal support the outer profile of which is coincident with that of the radially internal surface of the tyre that is wished to be produced. Said toroidal support is moved, preferably by a robotized system, between a plurality of stations in each of which through automated sequences, a particular tyre manufacturing step is carried out (see document EP 0 928 680 in the name of the same Applicant, for example).

The European Patent Application issued under No. 0 976 533 in the name of the same Applicant discloses a method and an apparatus for moulding and curing tyres for vehicle wheels in which a green tyre manufactured on a toroidal support is enclosed in the moulding cavity of a vulcanisation mould; subsequently, steam or other fluid under pressure is fed into at least one gap for fluid diffusion created between the outer surface of the toroidal support and the inner surface of the tyre, thereby imposing a radial expansion to said tyre that causes pressing of the latter against the inner surfaces of the moulding cavity. Following this pressing operation, suitable forming ridges set in the moulding cavity penetrate into the elastomeric material in the region of the tread band, to generate recesses and grooves such disposed as to form a desired tread pattern.

By a method of the above described type, the cured tyre can however show some faults, because the steam or other working fluid used for vulcanisation comes into direct contact with the innermost layer of the tyre, as for tyres directly assembled and cured on the same toroidal support there is not the effect of the vulcanisation bladder normally used when vulcanisation is carried out on tyres built by assembling semi-finished components without the aid of a toroidal support.

To overcome these drawbacks, the Applicant has already put into practice the above described methods through the teachings of document WO 2004/045837 according to which a green tyre is submitted to a preliminary step of pressing it against the toroidal support while simultaneously administering heat, to obtain at least partial vulcanisation of the innermost layer of the tyre itself and of the bead region. In this manner it is possible to subsequently carry out a moulding and vulcanisation step while expanding the tyre against the outer surfaces of the moulding cavity, without involving lack of homogeneity and of evenness in that tyre portion that is in contact with the toroidal support, which portion is the first to come into contact with the working fluid during vulcanisation. The working fluid used in the moulding and vulcanisation step in fact comes into contact with parts of the tyre that have already been partly cured and in which therefore the behaviour of the material is no longer plastic but almost elastic, thereby withstanding the fluid action without experiencing deterioration or deformations.

The Applicant has however perceived that also in the above described vulcanisation methods submitting the tyre to a preliminary pressing treatment against the toroidal support, surface unevennesses in the radially external parts of the tyre can occur, at least under particular work conditions.

According to the Applicant's perception, in fact, the preliminary pressing step against the toroidal support, aimed at obtaining an at least partial cross-linking of the inner tyre surface, can also cause partial cross-linking of the radially external surface portions of the tyre itself.

In more detail, the Applicant has noticed that closure of the tyre into the moulding cavity can cause the tread band to be partially penetrated by the forming ridges set in the moulding cavity for the purpose of creating the tread pattern so that, as a result, heat transfer and partial cross-linking of the tyre regions directly in contact with the forming ridges occur during the preliminary pressing step. Consequently, unevennesses are created in the elastomeric material constituting the tread band and correct adaptation of the material itself to the conformation of the moulding cavity during the subsequent moulding and vulcanisation step is impaired.

The Applicant has further observed that part of the fluid under pressure, nitrogen for example, admitted into the mould to cause the preliminary pressing treatment against the toroidal support can be entrapped between the outer surface of the tread band and the moulding cavity, in the grooves delimited by the forming ridges to form the pattern blocks on the tyre tread band. Therefore gaseous pockets are created that can be hardly evacuated during the subsequent moulding and vulcanisation step and can cause geometric unevennesses in the finished product.

The Applicant has also become aware of the fact that, in the moulding and vulcanisation steps of tyres having a marked transverse curvature, for two-wheeled vehicles for example, it would be better to use a mould that, by virtue of its geometrical features, is able to ensure a high degree of circularity and uniformity in the cured tyre.

The Applicant has realised that the above described problems can be overcome through use of a mould the moulding cavity of which is defined by two half shells that can be axially moved close to each other until they mutually mate, preventing the forming ridges from coming into contact with the radially external surface of the tyre tread band in the period elapsing between closure of the tyre into the moulding cavity and the moulding and vulcanisation step of said tyre against the walls of the moulding cavity itself.

In accordance with the present invention, the Applicant has found that, by use of a mould of the above described type and by keeping the forming ridges radially spaced apart from the radially external surface of the tread band during said preliminary pressing step against the toroidal support the elastomeric material is prevented from prematurely cross-linking in the outermost layers of the tyre thus impairing a correct implementation of the moulding step.

Therefore, important improvements can be achieved in the geometrical and structural uniformity of the finished product, in particular when two-wheeled vehicles are concerned.

In addition, the forming ridges can be advantageously set so as to be slidably guided in through slits arranged in the half shells. In this way any residual fluid can be evacuated from the moulding cavity, through gaps defined between the through slits and the forming ridges.

Subsequently, the forming ridges are moved close to the tread band when the tyre moulding and vulcanisation step begins, with possible expansion of said tyre against the moulding cavity.

Also avoided are geometrical faults due to fluid stagnation between the radially external surface of the tread band and the grooves delimited between the forming ridges.

In addition by moving the forming ridges away from the tread band before opening of the mould when vulcanisation is over, disengagement and removal of the finished tyre from the moulding cavity is made simpler, even when the tread band has a tread pattern provided with substantially circumferential grooves and/or a rather complicated tread pattern.

In more detail, in accordance with a first aspect, the invention relates to a method of manufacturing pneumatic tyres for vehicle wheels, comprising the steps of: setting a green tyre comprising a tread band having a radially external surface, on a toroidal support provided with an outer surface conforming in shape to an inner surface of the tyre itself; setting a vulcanisation mould having a moulding cavity defined by two half shells adapted to be moved close to each other in an axial direction, and circumscribed by centripetally approachable circumferential sectors carrying forming ridges facing a geometric axis of the moulding cavity and movable in through slits set in the half shells; closing the tyre into the moulding cavity; pressing the tyre against the outer surface of the toroidal support; administering heat to the inner surface of the tyre pressed against the toroidal support, keeping the circumferential sectors spaced apart from the radially external surface of the tread band; centripetally approaching the circumferential sectors of the mould to cause at least partial penetration of the forming ridges into the radially external surface of the tread band of the tyre; pressing the radially external surface of the tread band of the tyre against a radially internal surface of the moulding cavity; administering heat to the tyre penetrated by the forming ridges of the circumferential sectors.

In accordance with a second aspect, the invention relates to an apparatus for manufacturing pneumatic tyres for vehicle wheels, comprising: a toroidal support having an outer surface conforming in shape to the inner surface of a green tyre under working comprising a tread band provided with a radially external surface; devices for arranging the green tyre on the toroidal support; a vulcanisation mould having two half shells adapted to be moved close to each other to define a moulding cavity, and centripetally approachable circumferential sectors circumscribing the moulding cavity and carrying forming ridges facing the geometric axis of the moulding cavity and movable in through slits set in said half shells; devices for closing the tyre into the moulding cavity; devices for pressing the tyre enclosed in the moulding cavity against the outer surface of the toroidal support; first devices for administering heat to the inner surface of the tyre pressed against the toroidal support; driving devices to be activated subsequently to closure of the tyre into the moulding cavity to cause translation of the circumferential sectors between a first work condition at which the forming ridges are radially spaced apart from the radially external surface of the tread band of the tyre enclosed in the moulding cavity, and a second work condition at which the forming ridges penetrate at least partly into the radially external surface of the tread band; devices for pressing the radially external surface of the tread band of the tyre against a radially internal surface of the moulding cavity; second devices for administering heat to the tyre penetrated by the forming ridges of the circumferential sectors.

Further features and advantages will become more apparent from the detailed description of a preferred, but not exclusive, embodiment of a method of manufacturing tyres and an apparatus for putting said method into practice, in accordance with the present invention.

This description will be set out hereinafter with reference to the accompanying drawings, given by way of non-limiting example, in which:

FIG. 1 is a fragmentary diametrical section view of a moulding and curing apparatus in accordance with the present invention, set in an open condition to enable introduction and removal of a tyre under working;

FIG. 2 shows the apparatus in FIG. 1 in a closed condition, in a step of pressing the tyre under working against the outer surface of a toroidal support;

FIG. 3 shows the apparatus in a step subsequent to that in FIG. 2, in a different diametrical section plane, during pressing of the tyre against the inner surfaces of the moulding cavity.

With reference to the drawings, a moulding and curing apparatus for tyres of vehicle wheels in accordance with the present invention has been generally denoted at 101.

Apparatus 101 comprises a vulcanisation mould 102 operatively associated with a casing 103 and having a lower half shell 130 a and an upper half shell 130 b in engagement with a base 103 a and a closing portion 103 b of casing 103 respectively, or other suitable devices to close a tyre under working 50 into the mould itself.

The base 103 a and the closing portion 103 b, together with the respective lower 130 a and upper 130 b half shells are in fact movable relative to each other between an open condition at which they are mutually spaced apart as shown in FIG. 1, to enable introduction of the tyre 50 to be cured into the mould 102, and a closed position at which, as shown in FIGS. 2 and 3, they are disposed close to each other at a mutually mating position to close tyre 50 into a moulding cavity 104 having inner walls reproducing the geometrical contour to be given to the tyre at the end of the moulding and curing process.

Preferably the half shells 130 a, 130 mutually mate according to an undulated surface of the substantially sinusoidal type, to advantageously allow angular centring of tyre 50 in the moulding cavity 104.

In detail, the half shells 130 a, 130 b face each other and have side portions 132 a, 132 b set to operate against the opposite sides of tyre 50, so as to form the outer surfaces of the tyre sidewalls 51.

Extending from the side portion 132 a, 132 b of each half shell 130 a, 130 b in an arched profile is a radially external portion 133 a, 133 b designed to operate on a so-called tread band 52 of tyre 50.

In a preferential embodiment, apparatus 101 is particularly suitable to manufacture tyres 50 of a marked transverse curvature, for two-wheeled vehicles for example, such as tyres for motorcycles.

In fact, as compared with tyres for four-wheeled vehicles, tyres for two-wheeled vehicles are distinguishable for their marked transverse curvature. This transverse curvature is usually defined by the particular value of a so-called curvature ratio “R”, i.e. the ratio of the distance “D” existing between the radially external point of the tread band and the line passing through the laterally opposite extremities of the tread band itself measured in the equatorial plane of the tyre, to the distance “L” measured along the tyre chord between said extremities. In tyres for two-wheeled vehicles, the value of the curvature ratio is generally at least as high as 0.15 and it is usually in the order of about 0.3 for rear tyres an even higher until about 0.45 for front tyres, against a value usually in the order of about 0.05 when motor vehicle tyres are concerned.

Correspondingly, the moulding cavity 104 defined by the half shells 130 a, 130 b disposed close to each other in the closed condition, has a given curvature ratio “Rs” between the following two distances: the distance “Ds”, measured in an equatorial plane Y-Y (substantially coincident with the equatorial plane of tyre 50 within the moulding cavity 104), existing between a point of the radially internal surface of the moulding cavity (without considering the forming ridges) and the straight line lying in a plane radial to a geometric axis X-X of the moulding cavity 104 and passing through the transition points 134 a, 134 b belonging to the same radial plane between the side portions 132 a, 132 b and the radially external portions 133 a, 133 b; and the distance “Ls” measured along the chord of the moulding cavity 104 between said transition points.

In moulds for tyres for two-wheeled vehicles, the value of said curvature ratio Rs is preferably at least as high as 0.15 and is usually in the order of about 0.3 for rear-tyre moulds, and even higher until about 0.45 for front-tyre moulds, against a value usually in the order of about 0.05 when moulds for motor vehicle tyres are concerned.

Mould 102 further comprises at least one crown of circumferential sectors 140 circumscribing the moulding cavity 104 and set to operate on a radially external surface of the tread band 52 of tyre 50, to therein create a series of cuts and longitudinal and/or transverse grooves that are suitably disposed according to a desired “tread pattern”. To this aim the circumferential sectors 140 mounted externally of the radially external portions 133 a, 133 b, carry forming ridges 141 facing said geometric axis X-X of the moulding cavity 104 and designed to act on the tread band 52 by means of through slits 142 set in the radially external portions 133 a, 133 b of the half shells 130 a, 130 b.

Preferably, each circumferential sector 140 is axially divided into a lower half 140 a and an upper half 140 b, each in engagement with one of the lower 130 a and upper 130 b half shells respectively, at perimetral slide surfaces 131 a, 131 for example that, at least in the closed condition, are adapted to guide the circumferential sectors 140 so as to enable radial movement of same relative to the geometric axis X-X of the moulding cavity 104.

Further associated with the circumferential sectors 140 are driving devices 150 to be activated subsequently to closure of tyre 50 into the moulding cavity 104, i.e. when the half shells 130 a, 130 b are in the closed condition, to cause radial translation of the circumferential sectors between a first work condition at which, as shown in FIG. 2, they are radially spaced apart from the geometric axis X-X of the moulding cavity 104, and a second work condition at which, as shown in FIG. 3, the circumferential sectors 140 are moved radially close to said geometric axis X-X, preferably in circumferential abutment relationship against each other.

In more detail, in the first work condition the forming ridges 141 carried by the circumferential sectors 140 are radially spaced apart from the respective half shells 130 a, 130 b and therefore from the radially external surface of the tread band 52 of tyre 50 disposed in the moulding cavity 104. Preferably, as shown in FIG. 2, in this condition the forming ridges 141 are out of the through slits 142 or in any case do not project towards the inside of the moulding cavity 104 to an important extent. As shown in FIG. 3, in the second work condition the circumferential sectors 140 on the contrary are disposed radially close to each other so that the forming ridges 141 penetrate at least partly into the tread band 52.

Preferably, the driving devices 150 comprise at least one sector-carrying ring 151 a, 151 b that is axially movable relative to the moulding cavity 104 and has at least one frustoconical surface 155 slidably engaging the circumferential sectors 140 to cause radial translation of the latter between the first and second work conditions, following an axial movement of the sector-carrying ring itself. In more detail, in the embodiment shown by way of example two sector-carrying rings are provided, i.e. a lower sector-carrying ring 151 a and an upper sector-carrying ring 151 b, associated with the lower and upper halves, 140 a and 140 b, respectively of the circumferential sectors 140.

Axial movement of each sector-carrying ring 151 a, 151 b can be obtained by means of pusher members operating on control rods 153 a, 153 b slidably engaged through the casing 103 of mould 102. More particularly, in the embodiment herein shown the pusher members comprise a plurality of first fluid-operated actuators 152 a, 152 b that are circumferentially distributed and externally fastened to the base 103 a and the closing portion 103 b respectively. Each actuator 152 a, 152 b operates on the respective control rod 153 a, 153 b by means of respective idler arms 154 a, 154 b pivoted on the base 103 a and the closing portion 103 b, respectively.

As an alternative to the above description, the driving means 150 can be set to directly operate exclusively on one of the lower and upper halves 140 a and 140 b of each circumferential sector 140, movement of the other half being obtained by dragging of the one half controlled by the driving means.

Also provided can be locking devices 160 to be activated for fixing positioning of the circumferential sectors 140 to the second work position. These locking devices 160 can for example comprise one or more stop blocks 161 a, 161 b carried by auxiliary control rods 162 a, 162 b slidably engaged through the casing 103, and movable upon command of auxiliary actuators 163 a, 163 b between a first work position at which they release axial movement of the respective sector-carrying ring 151 a, 151 b and a second work position at which they act against a radial shoulder 164 a, 164 b carried by the sector-carrying ring itself to lock the latter to the second work position as shown in FIG. 3. The stop blocks 161 a, 161 b can operate in thrust relationship against at least one frustoconical surface exhibited by the radial shoulder 164 a, 164 b so as to exert a constant action on the sector-carrying ring 151 a, 151 b in order to maintain the circumferential sectors 140 centripetally pushed towards axis X-X.

Due to radial moving apart of the circumferential sectors 140 with the mould 102 in the open conditions, easy introduction of tyre 50 to be cured and/or removal of the cured tyre is enabled through an access opening 170 defined between the upper 130 b and lower 130 a half shells in the open condition, without involving mechanical interferences between tyre 50 and the forming ridges 141 of the circumferential sectors themselves.

Apparatus 101 further contemplates use of at least one toroidal support 10 of metal material or other substantially rigid material, having an outer surface substantially reproducing the shape of the inner surface of tyre 50. The toroidal support 10 conveniently consists of a drum that can be split up, i.e. made up of circumferential sectors at least some of which are centripetally movable to dismantle the toroidal support itself and enable easy removal of same from tyre 50 when working has been completed.

Apparatus 101 further involves at least one duct 110 to feed a primary working fluid under pressure, such as steam, nitrogen or other substantially inert gas or a mixture thereof, to be used, as better illustrated in the following, for tyre moulding and curing.

Also preferably present in apparatus 101 are heating devices for mould 102, preferably in the form of a plurality of ducts 105 for passage of a heating fluid, associated with the half shells 130 a, 130 b and/or the circumferential sectors 140, respectively.

Preferably, also present in apparatus 101 is a hermetically sealed device suitable to contain the toroidal support 10 on which a green tyre 50 has been previously built.

As shown in the accompanying drawings, said hermetically sealed device can be, in a preferred embodiment, enclosed and integrated into said mould 102 defining a hermetically sealed cavity within the mould itself.

Preferably, said mould 102 in this case comprises at least one circumferential gasket 107 put on the opposite surfaces of base 103 a and of the closing portion 103 b.

Said circumferential gasket 107 can be embodied by an O-ring or preferably a series of superposed metal rings having a sealing element placed between the opposite surfaces thereof and able to resist pressures and temperatures as required by the method described in the following.

A device for feeding a secondary working fluid such as air, nitrogen or other substantially inert gases, is operatively associated with said mould 102. Said device comprises at least one delivery duct 108 and one exhaust duct 109 for feeding and evacuating said secondary working fluid under pressure to and from said mould 102 respectively, for pressing the inner surface of said green tyre 50 from inside to outside, against the outer surface of said toroidal support 10, as better described in the following.

Duct 110 is operatively associated with at least one passage device by a connecting duct 111 for example, that is formed in at least one of the centring shanks 11 of said toroidal support 10, to enable spreading of said primary working fluid under pressure within said toroidal support 10.

Said passage device is provided with suitable branches formed in the toroidal support 10 and by which said primary working fluid reaches a plurality of ducts (not shown) opening onto the outer surface of the toroidal support itself, through the gaps present between said circumferential sectors of the toroidal support 10, for example.

Preferably, a duct 112 adapted to evacuate the primary working fluid and/or possible condensate is then provided at the lower part of said moulding cavity 104.

In accordance with the method of the invention, the green tyre 50 is disposed on the toroidal support 10 before the latter is introduced together with the tyre itself, into the vulcanisation mould 102 set in the open condition.

In particular, arrangement of tyre 50 on the toroidal support 10 can be conveniently obtained by manufacturing the tyre directly on the support itself. In this manner the toroidal support 10 is advantageously utilised as a rigid shape for forming the different components such as liner, carcass plies, reinforcing structures to the beads, belt strips, sidewalls 51 and tread band 52 co-operating in forming tyre 50. More specifically, said components of tyre 50 are preferably made by suitable working units carrying out laying on said toroidal support 10 of elementary semi-finished products such as, by way of example, continuous elongated elements of elastomeric materials and strip-like elements of elastomeric material internally comprising at least one textile or metallic cord. For example, the tread band 52 can be obtained by winding said continuous elongated element of elastomeric material around the rotation axis of the toroidal support 10, in the form of coils disposed in side by side and/or superposed relationship or following another predetermined path.

Further details on the modes of laying the components of tyre 50 on the toroidal support 10 are for example described in the European Patent Application issued under No. 0 929 680 in the name of the same Applicant.

The toroidal support 10 carrying the green tyre 50 is transferred to the inside of mould 102 manually or with the aid of a robotized arm (not shown) or in any other manner, through the opening access 170 defined between the upper 130 b and lower 130 a half shells in the open condition.

Following axial movement of the closing portion 103 b towards base 103 a, the upper half shell 130 b is brought into abutment against the lower half shell 130 a, causing closure of tyre 50 into mould 102.

When closure has been completed, the circumferential sectors 140 are in the first work condition, the forming ridges 141 being spaced apart from the radially external surface of the tread band 52 of tyre 50.

Through duct 108 said secondary fluid under pressure is sent into the moulding cavity 104. The secondary working fluid therefore takes up the space included between the outer surface of said green tyre 50 and the inner surface of the moulding cavity 104. Substantially simultaneously, said primary working fluid under pressure is sent into said toroidal support 10 at a lower pressure than that of said secondary working fluid. After a short transient stage, the pressure differential resulting from what above illustrated is preferably maintained for some minutes. Since the primary working fluid is at a lower pressure, it will stay at the inside of said toroidal support 10 without escaping from the previously described ducts formed therethrough. In this way, during this step the green tyre 50 is pressed from outside to inside, so that the inner surface thereof preferably comprising the liner is pressed against the outer surface of the toroidal support 10.

Preferably said primary working fluid, that in this step is preferably formed of steam, is fed to a temperature generally included between about 170° C. and 210° C.

During said period of time, the primary working fluid heats the toroidal support 10 and the latter transmits heat to the inner surface of the tyre, then to the region of the beads and preferably to the liner.

In addition or as an alternative to the primary working fluid conveyed through the feeding duct 110, different devices for administering heat to the inner surface of the tyre can be provided, and they for example comprise electric resistors for heating the toroidal support 10.

Heating carried out through the toroidal support 10 does not fully cure said parts of tyre 50 but in any case it is sufficient to give the parts themselves elasticity features. In particular, the carcass ply or plies are well anchored to the beads, and the inner surface of the tyre, preferably the liner, becomes elastic enough to withstand the subsequent pressures of the moulding and curing process illustrated in the following, without being torn.

This pressing step of tyre 50 against the outer surface of the toroidal support 10, and simultaneous administration of heat to the inner surface of the tyre itself, terminates with evacuation of the secondary working fluid by means of the exhaust duct 109.

It will be appreciated that the absence of a direct contact between the forming ridges 141 and the tread band 52 during the pressing step of tyre 50 against the toroidal support 10 eliminates the risk of directly transmitting heat to the outer surface of the tread band 52. Therefore triggering of premature cross-linking on the tread band 52, which will give rise to footprints different from the desired ones on the finished tyre, is avoided, also due to a “memorisation” effect of the shape and position of the coils formed by the continuous elongated element wound on the toroidal support so as to form the tread band 52.

In addition, exhaust interstices defined between the through slits 142 and the forming ridges 141 allow easy evacuation of the secondary working fluid under pressure from the moulding cavity 104 at the end of the pressing step of the tyre against the toroidal support 10, without any risk of forming stagnation of fluid under pressure between the outer surface of the tread band 52 and the moulding cavity itself, in the spaces circumscribed by the forming ridges 141. Also the distance between the forming ridges 141 and the tread band 52, as well as the space between the circumferential sectors 140 due to the fact that they remain in the first work condition, promotes quick evacuation of the secondary working fluid under pressure between tyre 50 and the moulding cavity 104.

When the pressing step has been completed with evacuation of the working fluid utilised as above illustrated, the driving devices 150 are operated and they cause a centripetal approaching of the circumferential sectors 140 from the first to the second work condition at which the forming ridges 141 penetrate at least partly into the tread band 52. It will be recognised that in the apparatus in accordance with the invention the centripetal movement of the circumferential sectors 140 is therefore uncoupled from the movement consequent to the step of closing mould 102 between base 103 a and the closing portion 103 b.

The auxiliary blocks 161 a, 161 b are driven by the respective actuators 163 a, 163 b to fix positioning of the circumferential sectors 140 to the second work condition, until the end of the subsequent step aimed at complete moulding and curing of tyre 50, which operation starts concurrently with fixing of the circumferential sectors 140 to the second work condition.

The above step starts by increasing the pressure of said primary working fluid to a value included between about 18 and about 35 bars, preferably between about 26 and about 28 bars, in order to mould and cure tyre 50 with the desired pulling strength on the carcass ply.

During this step the primary working fluid preferably comprises a steam and nitrogen mixture, even if it can consist of either steam alone or steam admixed with air or other substantially inert gases, or also of one or more gases such as air, nitrogen and other substantially inert gases.

The pressure generated by said primary working fluid reaches a diffusion gap (not shown) created between the outer surface of the toroidal support 10 and the inner surface of the tyre to be cured.

In a preferential alternative embodiment, the diffusion gap is created directly following expansion of the tyre caused by effect of the thrust exerted by said primary working fluid.

Thus pressing of the tyre against the walls of the moulding cavity 104 is carried out concurrently with an expansion imposed to the tyre itself, until bringing the outer surface of the latter to fully adhere to the inner walls of the moulding cavity 104, the forming ridges 141 fully penetrating into the tread band 52.

In this step too, the exhaust interstices resulting from a mechanical clearance or embodied by grooves suitably set between the forming ridges 141 and the respective through slits 142, promote evacuation of the possible fluid still present between the outer surface of the tread band 52 and inner surface of the moulding cavity 104.

Since the elastomeric material forming the tread band 52 is in a raw state, i.e. devoid of important cross-linking triggers, perfect adaptation and optimal contact of the material itself against the inner walls of the moulding cavity 104 is obtained. In addition, said pressing action takes place concurrently with administration of heat to cause cross-linking of the elastomeric material forming tyre 50 and the consequent geometric and structural definition of the tyre itself.

Advantageously, said primary working fluid determining the desired pressure, while enabling moulding of the tyre also supplies the necessary heat for vulcanisation.

When vulcanisation has been completed, the primary working fluid is evacuated from mould 102 and the driving devices 150 move the circumferential sectors 140 apart, bringing them back to the first work position, so as to cause disengagement of the latter from the corresponding cuts and/or grooves made by them in the tread band 52. Thus the subsequent mutual moving apart of the half shells 130 a, 130 b is facilitated as well as release of tyre 50 from mould 102, even when the tyre has a tread pattern abounding in grooves and/or cuts oriented in a substantially circumferential direction. 

1-37. (canceled)
 38. A method of manufacturing a pneumatic tyre for a vehicle wheel, comprising the steps of: setting a green tyre comprising a tread band having a radially external surface, on a toroidal support provided with an outer surface conforming in shape to an inner surface of the tyre; setting a vulcanisation mould having a moulding cavity defined by two half shells adapted to be moved close to each other in an axial direction and circumscribed by centripetally approachable circumferential sectors carrying forming ridges facing a geometric axis of the moulding cavity and movable in through slits set in the half shells; closing the tyre into the moulding cavity; pressing the tyre against the outer surface of the toroidal support; administering heat to the inner surface of the tyre pressed against the toroidal support keeping the circumferential sectors spaced apart from the radially external surface of the tread band; centripetally approaching the circumferential sectors of the mould to cause at least partial penetration of the forming ridges into the radially external surface of the tread band of the tyre; pressing the radially external surface of the tread band of the tyre against a radially internal surface of the moulding cavity; and administering heat to the tyre penetrated by the forming ridges of the circumferential sectors.
 39. The method as claimed in claim 38, wherein the step of pressing the tyre against the outer surface of the toroidal support is carried out concurrently with administration of heat to the inner surface of the tyre.
 40. The method as claimed in claim 38, wherein closure of the mould into the moulding cavity is carried out through axial approaching of said half shells from an open condition at which the half shells are mutually spaced apart to form an opening for access of the tyre to the moulding cavity to a closed condition at which the half shells mutually mate.
 41. The method as claimed in claim 38, wherein the forming ridges carry out a translation in said through slits during centripetal approaching of said circumferential sectors.
 42. The method as claimed in claim 38, further comprising, during pressing of the radially outer surface of the tread band, the step of evacuating fluid from the moulding cavity through said through slits.
 43. The method as claimed in claim 38, wherein administration of heat to the tyre penetrated by the forming ridges of the circumferential sectors is carried out by admission of a primary working fluid into the toroidal support.
 44. The method as claimed in claim 38, wherein the step of pressing the radially external surface of the tread band against the radially internal surface of the moulding cavity takes place during administration of heat to the tyre penetrated by the forming ridges of the circumferential sectors.
 45. The method as claimed in claim 44, wherein pressing of the radially external surface of the tread band against the radially internal surface of the moulding cavity is carried out through admission of a primary fluid into a diffusion gap between the outer surface of the toroidal support and the inner surface of the tyre.
 46. The method as claimed in claim 38, wherein pressing of the tyre against the outer surface of the toroidal support is carried out through admission of a secondary fluid under pressure into the moulding cavity.
 47. The method as claimed in claim 38, wherein administration of heat to the inner surface of the tyre is carried out through heating of the toroidal support.
 48. The method as claimed in claim 47, wherein heating of the toroidal support is carried out by means of electric resistors.
 49. The method as claimed in claim 47, wherein heating of the toroidal support is carried out by means of a primary working fluid conveyed into the toroidal support.
 50. The method as claimed in claim 38, further comprising the steps of: moving the circumferential sectors apart to cause extraction of the forming ridges from the radially external surface of the tyre tread band; moving the half shells away from each other; and extracting the tyre from the mould.
 51. The method as claimed in claim 38, wherein the green tyre is directly formed on the toroidal support.
 52. An apparatus for manufacturing pneumatic tyres for vehicle wheels, comprising: a toroidal support having an outer surface conforming in shape to the inner surface of a green tyre under working conditions comprising a tread band provided with a radially external surface; devices for arranging the green tyre on the toroidal support; a vulcanisation mould having two half shells adapted to be moved close to each other to define a moulding cavity and centripetally-approachable circumferential sectors circumscribing the moulding cavity and carrying forming ridges facing the geometric axis of the moulding cavity and movable in through slits set in said half shells; devices for closing the tyre into the moulding cavity; devices for pressing the tyre enclosed in the moulding cavity against the outer surface of the toroidal support; first devices for administering heat to the inner surface of the tyre pressed against the toroidal support; driving devices to be activated subsequent to closure of the tyre into the moulding cavity to cause translation of the circumferential sectors between a first work condition at which the forming ridges are radially spaced apart from the radially external surface of the tread band of the tyre enclosed in the moulding cavity, and a second work condition at which the forming ridges penetrate at least partly into the radially external surface of the tread band; devices for pressing the radially external surface of the tread band of the tyre against a radially internal surface of the moulding cavity; and second devices for administering heat to the tyre penetrated by the forming ridges of the circumferential sectors.
 53. The apparatus as claimed in claim 52, wherein said half shells are mutually approachable between an open condition at which they are mutually spaced apart to form an opening for access of the tyre to the moulding cavity, and a closed condition at which the half shells mutually mate.
 54. The apparatus as claimed in claim 53, wherein matching of said half shells takes place following an undulated surface.
 55. The apparatus as claimed in claim 52, wherein said half shells each have perimetral surfaces slidably engaged with the circumferential sectors at least in the closed condition, to allow movement of the circumferential sectors between the respective first and second work conditions.
 56. The apparatus as claimed in claim 52, wherein said driving devices comprise at least one sector-carrying ring that is axially movable relative to the moulding cavity and has at least one cone-shaped surface slidably engaged with said circumferential sectors to cause translation of the sectors between said first and second work conditions following an axial movement of the sector-carrying ring.
 57. The apparatus as claimed in claim 56, wherein the driving devices further comprise pusher members operating on the sector-carrying ring by means of control rods slidably engaged through a casing of said mould.
 58. The apparatus as claimed in claim 57, wherein said pusher members comprise first fluid-operated actuators that are fixed relative to the casing.
 59. The apparatus as claimed in claim 58, wherein said first fluid-operated actuators operate on the control rods through idler arms pivoted on said casing.
 60. The apparatus as claimed in claim 52, further comprising locking devices to be activated in order to fix positioning of the circumferential sectors to the second work condition.
 61. The apparatus as claimed in claim 60, wherein said locking devices comprise at least one stop block carried by at least one auxiliary control rod slidably engaged through a casing of said mould and movable upon command of an auxiliary actuator between a first work position at which it releases the axial movement of the sector-carrying ring and a second work position at which it acts against a radial shoulder carried by the sector-carrying ring to lock the latter to the second work position.
 62. The apparatus as claimed in claim 61, wherein said at least one stop block operates in thrust relationship against at least one frustoconical surface exhibited by the radial shoulder, so as to exert an action on the sector-carrying ring tending to centripetally push the circumferential sectors toward the geometric axis of the moulding cavity.
 63. The apparatus as claimed in claim 52, wherein each circumferential sector comprises a lower half and an upper half each in engagement with one of said half shells.
 64. The apparatus as claimed in claim 52, wherein in the first work condition the forming ridges are positioned externally of the moulding cavity.
 65. The apparatus as claimed in claim 52, further comprising exhaust interstices defined between the through slits and the forming ridges to evacuate fluid from the moulding cavity during pressing of the radially external surface of the tread band.
 66. The apparatus as claimed in claim 52, wherein said second devices for administering heat to the tyre comprise at least one duct for feeding a primary working fluid into the toroidal support.
 67. The apparatus as claimed in claim 52, wherein said devices for pressing the radially external surface of the tread band against the radially internal surface of the moulding cavity act when the circumferential sectors are in the second work condition.
 68. The apparatus as claimed in claim 52, wherein said devices for pressing the radially external surface of the tread band comprise at least one duct for feeding a primary fluid into a diffusion gap between the outer surface of the toroidal support and the inner surface of the tyre.
 69. The apparatus as claimed in claim 52, wherein said devices for pressing the tyre against the outer surface of the toroidal support comprise at least one delivery duct for feeding a secondary fluid under pressure to the moulding cavity.
 70. The apparatus as claimed in claim 52, wherein the first devices for administering heat to the inner surface of the tyre comprise electric resistors for heating the toroidal support.
 71. The apparatus as claimed in claim 52, wherein the first devices for administering heat to the inner surface of the tyre comprise a duct for feeding a primary fluid into the toroidal support.
 72. The apparatus as claimed in claim 52, wherein the devices for setting the green tyre on the toroidal support comprise working units designed to form components of the tyre directly on the toroidal support.
 73. The apparatus as claimed in claim 52, wherein the moulding cavity, defined by the half shells disposed close to each other in a closed condition, has a curvature ratio of about 0.15 to about 0.3.
 74. The apparatus as claimed in claim 52, wherein the moulding cavity defined by the half shells disposed close to each other in a closed condition has a curvature ratio of about 0.15 to about 0.45. 